TURBOCHARGER INSTALLATION

PROCEDURE


  1. INSTALL INLET TURBO OIL PIPE SUB-ASSEMBLY


    1. B007WTIC01
      *a NG

      Install a new inlet turbo oil gasket to the turbocharger sub-assembly as shown in the illustration.

      Note

      Make sure that the inlet turbo oil gasket is installed in the correct direction.

    2. Install the inlet turbo oil pipe sub-assembly to the turbocharger sub-assembly with the 2 nuts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  2. INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY


    1. Install a new water by-pass gasket to the turbocharger sub-assembly.

    2. Temporarily install the No. 1 turbo water pipe sub-assembly to the turbocharger sub-assembly with the bolt and 2 nuts.

    3. B007YKEE02

      Tighten the bolt and nuts in the order shown in the illustration.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  3. INSTALL INLET COMPRESSOR ELBOW


    1. Install a new inlet compressor gasket to the turbocharger sub-assembly.

    2. Install the inlet compressor elbow to the turbocharger sub-assembly with the 2 nuts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  4. INSTALL TURBOCHARGER SUB-ASSEMBLY


    1. B007XA4C02
      *a Claw

      Install a new outlet No. 1 turbo oil gasket to the inlet turbo oil pipe sub-assembly as shown in the illustration.

      Note

      Make sure that the claws of the outlet No. 1 turbo oil gasket are facing the inlet turbo oil pipe sub-assembly.

    2. B007ZJFC02
      *a Protrusion

      Install a new exhaust manifold to head gasket to the cylinder head sub-assembly.

      Note

      Make sure that the protrusion of the exhaust manifold to head gasket is facing the cylinder head sub-assembly.

    3. Temporarily install the turbocharger sub-assembly to the cylinder head sub-assembly with 4 new nuts.

    4. B007Z6UE01

      Tighten the 4 nuts in the order shown in the illustration.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

    5. Connect the intake air control valve (air by-pass valve assembly) connector and wire harness clamp to the turbocharger sub-assembly.

    6. B00805U

      Connect the vacuum transmitting hose assembly to the waste gate valve actuator with bracket assembly.

      Note

      Make sure that the vacuum transmitting hose assembly is installed all the way to the bent portion of the pipe of the waste gate valve actuator.

  5. CONNECT INLET TURBO OIL PIPE SUB-ASSEMBLY


    1. Install a new No. 1 union bolt gasket to the union bolt.

    2. Connect the inlet turbo oil pipe sub-assembly to the cylinder block sub-assembly with the 2 bolts and union bolt.

    3. Tighten the 2 bolts and union bolt.

      Torque:
      Bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Union Bolt
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note

      If the link that connects the No. 1 union bolt gasket is broken, remove the link by using side cutters or a similar tool.

  6. CONNECT NO. 2 INTERCOOLER WATER HOSE


    1. B007ZQ6C01
      *a Up
      *b Front
      *c 90°
      *d Paint Mark
      *e 2 to 7 mm (0.0787 to 0.276 in.)

      Connect the No. 2 intercooler water hose to the No. 1 turbo water pipe sub-assembly and slide the clip to secure it.

      Note

      Make sure to connect the No. 2 intercooler water hose to its correct location. Connecting the No. 2 intercooler water hose to the wrong location may result in damage the turbocharger sub-assembly.

      Tech Tips


      • Engage the clip of the No. 2 intercooler water hose within the area shown in the illustration.

      • Make sure that the paint mark of the No. 2 intercooler water hose is positioned as shown in the illustration.

  7. CONNECT NO. 1 TURBO WATER HOSE


    1. B007Z7VC01
      *a Up
      *b Front
      *c 90°
      *d Paint Mark
      *e 2 to 7 mm (0.0787 to 0.276 in.)

      Connect the No. 1 turbo water hose to the No. 1 turbo water pipe sub-assembly and slide the clip to secure it.

      Note

      Make sure to connect the No. 1 turbo water hose to its correct location. Connecting the No. 1 turbo water hose to the wrong location may result in damage the turbocharger sub-assembly.

      Tech Tips


      • Engage the clip of the No. 1 turbo water hose within the area shown in the illustration.

      • Make sure that the paint mark of the No. 1 turbo water hose is positioned as shown in the illustration.

  8. INSPECT WASTE GATE VALVE ACTUATOR WITH BRACKET ASSEMBLY

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  9. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  10. ADD ENGINE OIL

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  11. ADD COOLANT (for Intercooler)

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  12. CHECK ENGINE OIL LEVEL

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  13. INSPECT FOR COOLANT LEAK (for Intercooler)

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  14. INSPECT FOR ENGINE OIL LEAK

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  15. INSPECT FOR EXHAUST GAS LEAK

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